DURASTAR DRAM30S1A User manual

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INSTALLATION MANUAL
AIR HANDLER UNIT: 30K to 60K
DRAM30S1A, DRAM36S1A, DRAM48S1A, DRAM60S1A
FILTER COVER
Model Number:
Serial Number:
Purchase Date:
Installing Contractor Company Name:
208/230V 1ph 60 HZ 24V / RS485 Communicating
NOTE
This manual only refers to the models listed above. If you are installing the DRAM18F1A or
DRAM24F1A please refer to the manual included with that unit.
TIP
Capture relevant information about your Durastar mini-split equipment before it is
installed and write it above for future reference.

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TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................................................3
WARNINGS ............................................................................................................................................................3
IMPORTANT SAFETY PRECAUTIONS ....................................................................................................4
OPERATING TEMPERATURES....................................................................................................................6
ACCESSORIES......................................................................................................................................................7
UNIT DIMENSIONS.............................................................................................................................................8
FILTER SIZE ...........................................................................................................................................................9
PARTS IDENTIFICATION .................................................................................................................................9
INSTALLATION PREPARATION.................................................................................................................10
AIR HANDLER INSTALLATION ..................................................................................................................18
DUCT REQUIREMENTS ..................................................................................................................................19
CONDENSATE PIPING INSTALLATION................................................................................................ 20
REFRIGERANT PIPING CONNECTION.................................................................................................. 22
WIRING OVERVIEW......................................................................................................................................... 28
ELECTRIC HEATER INSTALLATION (OPTIONAL).......................................................................... 28
AUXILIARY HEATER ELECTRICAL DATA............................................................................................ 29
CONFIRM ELECTRIC HEATER WIRING..................................................................................................31
ELECTRIC AUXILIARY HEATING WIRING DIAGRAMS ................................................................. 32
INDOOR UNIT WIRING ................................................................................................................................... 33
CONTROL LOGIC ............................................................................................................................................. 36
LED DISPLAY DEFINITIONS ....................................................................................................................... 38
DIP SWITCHES SETTINGS ........................................................................................................................... 39
AIR VOLUME TABLE ....................................................................................................................................... 42
POWER SPECIFICATIONS ........................................................................................................................... 46
FINAL CHECKS....................................................................................................................................................47
TEST RUN ............................................................................................................................................................. 48
WIRING DIAGRAM.............................................................................................................................................52
ERROR AND OPERATING CODES .......................................................................................................... 53

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WARNINGS
The warning symbol indicates cautionary information for the user. Extra care and
precautions should be taken to ensure the user's safety.
The pencil indicates any manufacturer notes relating to surrounding content. These may
include further clarifications or call-outs.
A light bulb symbol indicates suggested manufacturer tips for the user to get the most
out of the Durastar equipment and to accommodate the best user experience.
Symbols Used in This Manual
INTRODUCTION
To better serve you, please do the following before contacting customer service:
• If you received a damaged product, immediately contact the retailer or dealer that sold you the
product.
• Read and follow this owner's manual carefully to help you use and maintain your air handler.
• Read the troubleshooting section of this manual as it will help you diagnose and solve common
issues.
• Visit us on the web at www.durastar.com to download product guides and up-to-date
information.
• If you need warranty service, our friendly customer service representatives are available via
email at [email protected] or by telephone at 1-888-320-0706.

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IMPORTANT SAFETY PRECAUTIONS
Improper handling can cause serious damage or injury. Please read the following safety
information in its entirety.
Operation, Cleaning, and Maintenance Safety Precautions
• Children and people with reduced physical, sensory, or mental capabilities, or lack of experience
and knowledge, should only use this air handler if they are given supervision and instructions
concerning use of the air handler in a safe way and understand the hazards involved.
• Children should not play with the air handler.
• Never stick fingers, other body parts, or other objects into the air inlet or outlet. The internal fan
may be rotating at high speeds. This could result in injury.
• Installation and maintenance must be performed by qualified professionals. Otherwise, you may
experience personal injury or damage to the air handler and surrounding property.
• If an abnormal situation arises (like a burning smell), immediately turn off the air handler and
disconnect power at the circuit breaker immediately. Then contact your dealer or a qualified
professional for service.
• Do not climb onto or place objects on top of the outdoor unit.
• Do not install the air handler in a wet room such as a bathroom or laundry room. Too much
exposure to water could cause electrical components to short circuit.
• Do not operate the air handler with wet hands. This may cause electric shock.
• Turn off the device and disconnect the power before cleaning. Failure to do so can cause
electrical shock.
• Do not clean the air handler with excessive amounts of water.
• Do not clean the air handler with combustible cleaning agents. Combustible cleaning agents can
cause fire or deformation.
• Do not use flammable materials such as hair spray, lacquer, or paint near the air handler as they
may catch fire.
• Do not operate the air handler in places near combustible gases. Emitted gases may collect
around the air handler and cause an explosion.
• Do not use the air handler for any other purpose than its intended use.
• Turn off the air handler if you are not going to use it for a long time.
• Make sure that water can drain unhindered from the unit.
• Do not allow the air handler to operate for long periods of time with doors or windows open, or if
the humidity is very high.
• Do not expose your body directly to cool air for a prolonged period of time.
• If the air handler is used together with burners or other heating devices, thoroughly ventilate the
room to avoid oxygen deficiency and carbon monoxide build up.
• In certain environments, such as kitchens, server rooms, etc., the use of specially designed air-
conditioning units is highly recommended.
• As with any mechanical equipment, contact with sharp sheet metal edges can result in personal
injury. Take care while handling this equipment and wear gloves and protective clothing.

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NOTE
The allowed static pressure range of the air handler on site is 0-0.80 in-H2O (0-200 Pa).
The airflow decreases below 0.80 in WC or 200Pa. System design should allow for the
increased resistance as filters become dirty.
The data below represents the static pressures at full required air flow used for AHRI
testing. 18-24k: 0.5 in-H2O(125Pa) 30-36k: 0.5 in-H2O(125Pa) 48-60k: 0.5 in-H2O(125Pa)
Electrical Safety
• The product must be properly grounded at the time of installation, or electrical shock may occur.
• If there is a serious safety issue with the power supply, stop work immediately. Explain your
reasoning to the client, and refuse to install the unit until the safety issue is properly resolved.
• For all electrical work, follow all local and national wiring standards, regulations, and the
Installation Manual. Connect cables tightly, and clamp them securely to prevent external forces
from damaging the terminal. Improper electrical connections can overheat and cause fire, and
may also cause shock. All electrical connections must be made according to the Electrical
Connection Diagram located on the panels of the indoor and outdoor units.
• All wiring must be properly arranged to ensure that the control board cover can close properly. If
the control board cover is not closed properly, it can lead to corrosion and cause the connection
points on the terminal to heat up, catch fire, or cause electrical shock.
• If connecting power to fixed wiring, an all-pole disconnection device which has at least 1/8"
(3mm) clearances in all poles, a leakage current that may exceed 10mA, a residual current
device (RCD) that has a rated residual operating current not exceeding 30mA, and a
disconnection must be incorporated in the fixed wiring in accordance with the wiring rules.
• Only connect the unit to an individual branch circuit. Do not connect another appliance to
that circuit.
• No other equipment should be connected to the same power circuit.
• Power voltage should be within 90-110% of rated voltage. Insufficient power supply can cause
malfunction, electrical shock, or fire.
• Installation of an external surge suppressor at the outdoor disconnect is recommended.
• The air handler’s circuit board (PCB) is designed with a fuse to provide over current protection.
The specifications of the fuse are printed on the circuit board.
• Do not let wires touch or rest against refrigerant tubing, the compressor, or any moving parts
within the unit.
• To avoid getting an electric shock, never touch the electrical components soon after the power
supply has been turned off.
• After turning on the power, always wait 10 minutes or more before you touch the
electrical components.
• Make sure that you do not cross your electrical wiring with your signal wiring. This may cause
distortion, interference or possibly damage to circuit boards.
• Connect the outdoor wires before connecting the indoor wires.
WARNING
Before performing any electrical or wiring work, turn off the main power to the
system.

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Installation Safety
• Installation must be performed by an authorized dealer or specialist. Defective installation can
cause water leakage, electrical shock, or fire.
• Installation must be performed according to the installation instructions. Improper installation
can cause water leakage, electrical shock, or fire. (In North America, installation must be
performed in accordance with the requirement of NEC and CEC by authorized personnel only.)
• Contact an authorized service provider for repair or maintenance of this unit. This appliance shall
be installed in accordance with national wiring regulations.
• Only use the included accessories, parts, and specified parts for installation. Using non-standard
parts can cause water leakage, electrical shock, fire, and can cause the unit to fail.
• Install the unit in a firm location that can support the unit’s weight. If the chosen location cannot
support the unit’s weight, or the installation is not done properly, the unit may fall and cause
serious injury and damage.
• Install drainage piping according to the instructions in this manual. Improper drainage may
cause water damage to your home and property.
• For units that have an auxiliary electric heater, do not install the unit within three (3) feet of any
combustible materials.
• Do not install the unit in a location that may be exposed to combustible gas leaks. If combustible
gas accumulates around the unit, it may cause fire.
• Do not turn on the power until all work has been completed.
• When moving or relocating the air handler, consult experienced service technicians for
disconnection and re-installation of the unit.
• Excessive Weight Hazard - Use two (2) or more people when moving and installing the unit.
Failure to do so can result in back or other type of injury.
Your air handler is designed to operate in the following indoor and outdoor temperatures. When
your air handler is used outside of the following temperature ranges, certain safety features may
activate and turn off the unit to protect it from damage. We strongly suggest keeping the unit
plugged in at all times when temperatures are below 32°F (0°C) for smooth operation.
TEMPERATURE RANGES
COOL mode HEAT mode DRY mode
Indoor Air
Temperature
60°F - 90°F
(16°C - 32°C)
32°F - 86°F
(0°C - 30°C)
50°F - 90°F
(10°C - 32°C)
Outdoor Air
Temperature
5°F - 122°F
(-15°C - 50°C)
-13°F - 75°F
(-25°C - 24°C)
32°F - 122°F
(0°C - 50°C)
To further optimize the performance of your unit, do the following:
• Keep doors and windows closed.
• Limit energy usage by using TIMER ON and TIMER OFF features.
• Do not block air inlets or outlets.
• Regularly inspect and clean air filters.
OPERATING TEMPERATURES

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INCLUDED INSTALLATION ACCESSORIES
The air conditioning system comes with the following accessories. These are usually packaged in
the air outlet. Remove before install.
FIELD SUPPLIED INSTALLATION ACCESSORIES
The following installation accessories are required and must be purchased separately.
• Refrigerant piping (line set)
• Filter
• Indoor and outdoor connection wire
• Outdoor power supply cord
• Drain pipe
• Pipe and cable wrapping tape
• Wall hole sleeve and cover
• Putty
• Wiring u-lugs
ACCESSORIES
ACCESSORY QUANTITY IMAGE ACCESSORY QUANTITY IMAGE
Manual 3 Cable Ties 2
Remote Control 1 Foam 4
Battery 2 Flare Nut 2
Wired Remote
Controller (accs
included)
1Braze To Flare
Adapter 2
Drain Fitting 1 Gasket 1
NOTE
The Durastar wired control (DRSTAT100) functions as an IR receiver for the handheld
remote. If the remote is not used, it must be retained with the indoor unit to adjust
parameters and for troubleshooting.

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TOOLS NEEDED
The following tools are required for installation.
• Phillips screwdriver
• Drill with 2 1/2" or 3 1/2" (indoor unit model depending) core bit
• Vacuum pump
• HVAC manifold gauge set
• Micron Gauge
• Refrigerant leak detector
• Copper pipe cutter
• Flaring tool
• Burr reamer
• Crescent or spanner wrench
• Hexagonal wrench set
• Torque wrench
• Multimeter
• Electro-probe
• Level
• Hammer
• Wire strippers
• Wire crimper
A
B
C
UNIT DIMENSIONS
Model BTU
Dimensions
A (Height)
in (mm)
B (Depth)
in (mm)
C (Width)
in (mm)
D
in (mm)
E
in (mm)
30K - 48K 49 (1245) 21 (533) 21 (533) 19-5/16
(490)
10-1/4
(260)
60K 53 (1346) 21 (533) 24-1/2
(622)
22-7/8
(580)
10-1/4
(260)

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PARTS IDENTIFICATION
NOTE
Illustrations in this manual are for explanatory purposes. The actual shape of your
equipment may vary slightly.
Filter and Filter Cover
(not shown)
Vertical
Drain
Horizontal
Drain
Suction Line
Liquid Line
Blower Fan and Motor
Evaporator
Air Outlet
Electrical
Components
Air Inlet
Electrical Heater
Compartment
Wire
Knockouts
FILTER SIZE
W
D
T
Nominal Size 30k-48k 60k
Width
in (mm)  ()  ()
Depth
in (mm)  ()  ()
Thickness
in (mm)  ()  ()

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INSTALLATION PREPARATION
DO NOT install the unit in:
• A wet environment. Excessive moisture can corrode the equipment, electrical components, and
cause electrical shorts.
• A coastal area with high salt content in the air.
• Areas with strong magnetic waves.
• Areas with oil drilling or fracking.
• Areas where there may be detergent or other corrosive gases in the air, such as bathrooms or
laundry rooms.
• Areas that store flammable materials or gas. Danger of explosion. Keep flammable materials
and vapors, such as gasoline, away from air handler.
• Areas where the air inlet or outlet of the indoor or outdoor unit may be obstructed.
Install the unit:
• With enough room for installation (connecting pipe and drainage) and maintenance.
• On a structure that can support its weight. If the structure is too weak, the unit may fall and
cause personal injury, unit and property damage, or death.
• With heating elements at least 18 inches above the floor in a garage. Failure to follow these
instructions can result in death, explosion, or fire.
• Cables and wires at least three (3) feet / one (1) meter from televisions or radios to prevent
static or image distortion. Depending on the appliances, a three (3) feet / one (1) meter distance
may not be sufficient.
SELECT INSTALLATION LOCATION
Before installing the indoor unit, you must choose an appropriate location. The following
standards must be met for an appropriate location for the unit.
NOTE
In addition, you must be aware of needed clearance space, installation direction, and
duct requirements. These items are covered in the following pages.
NOTE
The installation must be performed in accordance with the required local and national
standards. The installation may be slightly different in different areas.

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RECOMMENDED CLEARANCE AROUND UNIT
Horizontal Installations
Minimum clearance
of 1”/25.4mm on
all sides
Flexible
duct collar
The outlet side pipe length 59”/1.5m.
Horizontal installations
Vertical Installations
or
Vertical installations
When installed vertically (upward or downward), the lower end of the air outlet needs
to be connected to the L-shaped metal air duct and fastened by screws.
NOTE
Leave 24" of clearance in front of the cabinet doors for service space.

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DETERMINE INSTALLATION DIRECTION
The units can be installed in a vertical (up or down) or horizontal (right or left) configuration.
Vertical down and horizontal right will require changing the direction of the evaporator coils.
HorizontalVertical up
At least
3in(76mm)
Make sure wiring
is not laying in
the pan.
Airflow Direction
Horizontal left
Horizontal right
Upflow Downflow
NOTE
Vertical up and horizontal left installations do not need to change the direction of the
evaporator.
WARNING
It is recommended that a field supplied secondary drain pan is installed with a cut-off
switch. This is especially true when the installation is above or in a finished living space.
Local codes may require this.

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CONVERSION INSTRUCTIONS
FOR VERTICAL DOWN AND HORIZONTAL RIGHT INSTALLATION
STEP 1. REMOVE THE FILTER
Remove the filter door, then take the filter out.
STEP 2. REMOVE THE UPPER COVER
STEP 3. REMOVE THE EVAPORATOR COVER PLATE
Remove the bottom cover first, then remove the cover plate.
bottom cover
cover plate

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STEP 4. UNPLUG SENSORS T1, T2, T2A, T2B AND EEV FROM THE CONTROL BOARD
T1: Room temperature sensor
T2: Evaporator central sensor plug (only some models)
T2A: Evaporator input sensor plug (only some models)
T2B: Evaporator output sensor plug
EEV: Electronic Expansion Valve
T2
T2A&T2B
T1
EEV
30-48K model
T2
T2A
T2B
T1
EEV
60K model
T2
T2A
T2B
T1
EEV
30-48k Units 60k Units
STEP 5. UNLATCH THE ADJUSTABLE WIRE TIES ON THE T1, T2, T2A, T2B AND
EEV SENSOR CABLES.
Cut wire ties clamping wires to the coil as necessary to give slack.

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STEP 6. REMOVE THE EVAPORATOR AND DRAIN PAN.
STEP 7. ADJUST THE MOUNTING BRACKET TO THE PRE-DRILLED HOLES ON
THE LEFT SIDE OF THE CABINET.

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STEP 8. ROTATE THE COIL 180
DEGREES AND REINSTALL
THE EVAPORATOR AND
DRAIN PAN.
STEP 9. REINSTALL T1, T2 SENSOR
PLUGS AND TIE UP THE
SENSOR WIRES
The wire body needs to pass through the wire groove from
the drain pan and be stuck on the hook of the drain pan.
Cut the foam
gasket.
Remove knockouts
as shown in the
figure.
Hook the wire into
the buckle and go
down from the wire
slot.
Replace foam
gasket over wires.

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STEP 10. USE CABLE TIES TO FIX THE ROOM TEMPERATURE SENSOR WIRE TO
THE PIPES ON THE TOP OF THE EVAPORATOR.
Leave the sensor overhanging enough to not be affected by the temperature of the
pipe.
STEP 11. REINSTALL THE EVAPORATOR AND FILTER COVER PLATES.
Place unit into desired downflow or horizontal right position.
cable
ties

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STEP 1: CONSIDER DUCTWORK AND CONDENSATE PIPE INSTALLATION
REQUIREMENTS.
AIR HANDLER INSTALLATION
STEP 2: CONNECT CONDENSATE PIPE AND REFRIGERANT PIPING.
STEP 3: IF INSTALLING AN OPTIONAL AUXILIARY ELECTRIC HEATER, REFER TO
THE HEATER INSTALLATION SECTION FOR WIRING DIAGRAMS AND
EXPLANATION.
STEP 4: INSTALL OPTIONAL DEVICES.
Electrical
Control Box
Horizontal
Drains
Suction Line
Liquid Line
Upper
Cover
Vertical
Drains
STEP 5: CHECK AIR FLOW AND PERFORM A TEST RUN.

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DUCT REQUIREMENTS
• Air supply and return may be handled in one of several ways best suited to the installation (See
unit dimensions for duct inlet and outlet dimensions). The vast majority of problems encountered
with ducted systems can be linked to improperly designed or installed duct systems. It is critical
for the function and longevity of the unit that the ductwork is correctly designed and installed.
• Use flexible duct collars to minimize the transmission of vibration/noise into the conditioned
space.
• It is recommended to use lined return and supply duct near the unit when noise is a concern.
• The ductwork should be assembled according to the instructions.
• Wrap ductwork with insulation as specified by local codes, especially when installing in an
unconditioned space. This will avoid condensation formation and building damage.
• The supply air duct connection should be properly sized by use of a transition to match the
unit opening.
• All ducts should be suspended using flexible hangers and never fastened directly to the structure.
WARNING
Do not install this air handler or draw return air from where a gas-fueled appliance (i.e.,
water heater), or carbon monoxide-producing device (i.e., wood fireplace) is installed.
WARNING
There must be an airtight seal between the bottom of the air handler and the return air
plenum. Use fiberglass sealing strips, foil duct tape, caulking, or an equivalent sealing
method between the plenum and the air handler cabinet to ensure a tight seal.
NOTE
This unit is not designed for non-ducted (free-blow) applications

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CONDENSATE PIPING INSTALLATION
• Insulate all piping to prevent condensation, which could lead to water damage.
• The drainpipe is used to drain water away from the unit. If the drainpipe is bent or installed
incorrectly, water may leak and cause a water-level switch malfunction.
• In HEAT mode, the outdoor unit will discharge water. Ensure that the drain hose is placed in an
appropriate area to avoid water damage and icy conditions on walkways.
• DO NOT pull the drainpipe forcefully. This could disconnect it.
• Please apply sealant around the places where the wires, refrigerant pipes and condensate pipes
enter the cabinet.
• Use duct tape or flexible sealant to seal closed any space around the holes where the drain lines
exit the cabinet. Warm air must not be allowed to enter through any gaps or holes in the cabinet.
• After removal of drain pan plug(s), check drain hole(s) to verify that drain opening is fully open
and free of any debris. Also check to make sure that no debris has fallen into the drain pan during
installation that may plug up the drain opening.
• On units where the blower “draws” rather than “blows” air through the coil, traps must be installed
in the condensate drain lines (primary and auxiliary, if used). Traps prevent the blower from
drawing air through the drain lines into the air supply.
NOTE
A field-fabricated secondary drain pan, with a drain pipe to the outside of the building,
is required in all installations over a finished living space or in any area that may be
damaged by overflow from the main drain pan. The drain pan must be installed under the
entire unit and its condensate drain line must be routed to a location such that the user
will see the condensate discharge.
For horizontal installations, a secondary drain pan-not supplied-must be installed.